GLOBAL DIRECTOR OF LEAN MANUFACTURING/ENGINEERING & CONTINUOUS IMPROVEMENT LEADER
BSME, Lean Sensei Professional, with more than 20 years of senior-level Lean cultural transformational experience in establishing strategic operational plans, developing an implementing continuous process improvements, and utilizing Toyota Production System Principles that consistently exceeded performance metric targets for industry leading organizations such as: Magna Powertrain USA, Novartis Consumer Health and General Motors Corporation.
Experience includes, serving as Global Director Lean Manufacturing for Magna Powertrain USA in Troy, Michigan, with responsibility for leading Lean Manufacturing Deployment across 8 manufacturing facilities located in the U.S., Mexico, Austria, Germany, China and Korea that accomplished the following 3 items: 1) Developed a global manufacturing footprint analysis for a driveline systems group; 2) Improved die casting shop (8 presses) OEE from 58% to 65%; and 3) Created 4 model machining cells that increased labor efficiency 35% with high volume shaft machining cell reducing lead-time from 4 days to 90 minutes.
AREAS OF OPERATIONAL KNOWLEDGE
Precision Machining | Training Within-Industry (TWI) Methodology | Product-Process Optimization | Precision Scalable Assembly &
Testing Systems | APQP Supplier Development | New Manufacturing Plant Layout Optimization | Aluminum High Pressure Die Casting
Ø China Plant Startup: Entrusted by senior management with implementing TWI methodology for a Magna Powertrain plant startup in China that reduced the new employee on-boarding time from 104 hours to 56 Hours (46% reduction). Subsequently, launched 4 major programs (new plant, 2 new products, and recruited new team members) with 100% on-time delivery, Zero Customer Quality Complaints.
Ø EU Operational Performance Improvement: Led and facilitate a wide-array of shop floor improvement activities in aluminum die casting, precision machining, heat treat and assembly operations for Magna Powertrain, which delivered an annualized ¬ 3,045,000 labor savings, one-time inventory cost savings of ¬920,018 and improved operating efficiencies ranging between 13% 60%.
Ø Enterprise Value Stream Mapping: Received a 'Novartis Global Manufacturing & Supply Chain Excellence Award' for facilitating a global Extended Enterprise Value Stream Mapping workshop designed to dramatically improve the business case for the export of a new product to Russia. Consequently, realized $147,300 USD one-time inventory cost savings coupled with an annualized $248,200 USD logistic and warehousing cost savings.
Ø Product Quality Improvement: Led the on-site GM Product Engineering Team in Oshawa, Canada that focused on improving new vehicle quality as measured by the JD Power Initial Quality Survey. As a result of the implemented product quality improvements, the GM Oshawa Assembly Plant was recognized as one of the top 3 North American Plants by JD Power (Bronze 1998, Gold 2002, and Gold 2003), and became the most productive General Motors vehicle assembly plant as measured by Harbour and Associates.
WHAT OTHER'S SAY
"I have worked with Ray for many years and we worked on many projects together. His capability of coaching and leading a team was very impressive. He has a profound knowledge of the Toyota Production System and he was instrumental in rolling out the Lean principles at Magna Powertrain! His hands-on approach and working with people makes him an great leader."
...Stefan Urstöger, Head of Operational Excellence at Wienerberger AG
"It has been my pleasure to know and work with Ray through the years. Raymonds knowledge of his equipment and build requirements have always been at the highest level. His has always been a Get it Done Engineer and was a pleasure to work with on any project."
...Scott Harris, President - Member at Kasco Sales Services, LLC.
KEY AREAS OF COMPETENCIES
Material Flow/Labor/Equipment Optimization | Autonomous Maintenance & Single-Minute Exchange of Die (SMED) | Product & Plant Readiness | Capital Expenditures (CAPEX) Reduction | Capacity Analysis, Equipment Reuse | Manufacturing Floor Process Study (5Ms)
PROFESSIONAL EXPERIENCE & ACHIEVEMENTS
Gestamp North America Ú Troy, Michigan Ú 2017 to Present
Regional Continuous Improvement Leader Scope of duties consists of the ongoing development of a comprehensive Lean manufacturing deployment strategy across 9 U.S. manufacturing facilities that included leading cost reduction shop floor based activities that focused on reducing labor costs.
Optimized layout of new Greenfield facility designed to improve direct labor requirements by 45%, material-handling labor by 10%, and material route travel by 16.1% (5.7 km/day). As a result of layout, direct labor productivity increased from 3.49 units/man-hour to 6.29 units/man-hour.
Magna Powertrain USA Ú (2007 to 2010); (2012 to 2016)
Plant Manager, Lansing, Michigan (2015-2016) Primary duties focused on managing safety, quality, delivery and cost in a 3-shift operating facility with $325 million in annual sales. Oversaw major facility modifications, new assembly line, new CD Welder, tooling and process changes required for the new Audi Quattro Ultra System launch.
Ø Received plant recognition by General Motors for providing outstanding quality (3.2 ppm) and 100% on-time delivery in 2015 (less than 10% of suppliers met this criteria). Additionally, supported all key EH&S initiatives with the plant realizing and outstanding safety record of 572 days without an OSHA lost time accident and 552 days without a recordable injury.
Global Director - Lean Manufacturing, Troy, Michigan (2012-2015) Responsible for developing and executing global Lean manufacturing implementation strategy in 8 manufacturing facilities located in the U.S., Mexico, Austria, Germany, China and Korea.
Ø Achieved an 4.6% improvement of assembly first time quality globally through the deployment of Training-Within-Industry (TWI) training methodology in all Magna Powertrain Driveline Systems Facilities.
Director-Lean Manufacturing, Troy, Michigan (2007-2010) Charged with spearheading the Magna Powertrain global Lean manufacturing implementation strategy. Established model lines in 6 facilities to deepen understanding for management on TPS philosophy and implementation of sustainable improvements.
Ø Led a wide-array of shop floor process improvement workshops that improved labor efficiencies in 10 facilities, which generated annualized savings $5.69 million.
Novartis Lean Sensei Ú Lincoln, Nebraska Ú 2010 to 2012
Lean Sensei Responsibilities included deploying Toyota Production System (TPS) principles, continuous improvement and training activities that included standardizing work, problem solving, autonomous maintenance and value stream management at the site.
Ø Played a key role in leading a deployment of standardized work, problem solving, autonomous maintenance, SMED and value stream management at the site. Consequently, achieved a 26% improvement in packaging line OEE, with a reduction of changeover times between 32%-70%, and $2.51 million in material and labor savings in 20111.
General Motors Professional Experience Ú 1976 to 2007
General Motors Service Parts Operations, Engineering Manager-Lean Warehousing, Grand Blanc, Michigan (2004 to 2007)
General Motors Lean Business Solutions, Director-Midwest Operations, Fremont, California (2002-2004)
General Motors Manufacturing Engineering, Manufacturing Engineering Manager, Warren, Michigan (2001-2002)
New United Motor Manufacturing Inc (NUMMI), Senior Manufacturing Advisor, Fremont, California (1998-2001)
General Motors Product Engineering, Product Engineering Manager, Oshawa, Ontario Canada (1995 to 1998)
General Motors Vehicle Assembly Engineering, Advanced Manufacturing Engineer, Warren, Michigan (1988-1995)
General Motors Detroit/Hamtramck Assembly Center, Senior Manufacturing Engineer, Detroit, Michigan (1984-1988)
General Motor Cadillac Motor Car Division, Maintenance Supervisor, Detroit, Michigan (1983-1984); Facilities Engineer (1982-1983);
Project Engineer (1981-1982); Cooperative College Student (1976-1981)
ACADEMIC CREDENTIALS/CERTIFICATION & PROFESSIONAL DEVELOPMENT
BS, Mechanical Engineering, General Motors Institute (now Kettering University), Flint Michigan
Lean Manufacturing Certification, University of Michigan, Ann Arbor, Michigan
Leadership Development Program, Center for Creative Leadership, San Diego, California
"Ray has outstanding theoretical and practical know-how in lean manufacturing and operational excellence in global environments. He has a strong ability to connect and communicate with people on different levels and business functions. This is a key requirement in order to proliferate the idea of lean thinking within an organization. Ray is not only a very experienced Lean Expert; he also has proven to be a real Ambassador of Manufacturing excellence for the whole business. This skill but also his problem solving abilities and his analytical thinking made him a strong asset for the whole business."
...David Moser, Vice President Product Innovation EMEA at AssaAbloy